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Discussion Starter · #1 ·
This is a How-To for 2004 Dodge RAM 1500 Disc Brake Pads and Rotors removal and installation. The process is pretty much the same for all 3G RAM 1500s. As you can see in the photos, I replaced the OEM equipment with Brembro cross-drilled and slotted rotors and the Hawk HPS pads. I also decided to paint the calipers while they were off and easily cleaned prior to painting. Set aside about 1 hour for the 1st wheel and about 25 minutes for each remaining wheel. When doing the rear brakes, make sure the emergency brake is off.

ROTOR REMOVAL
1. Raise and support the vehicle.
2. Remove the tire and wheel assembly.
3. Remove the two bolts (13mm – Front 10mm – Rear) that secure the caliper.
4. Remove the caliper from the rotor by tilting it up and off the caliper adapter.
5. Do NOT let the caliper hang from the brake line. Damage to the brake line will be the result. Make sure to provide a suitable support!
6. Prior to compressing the piston(s) in the calipers, remove the top from the brake master cylinder. Cover it with a plastic bag to reduce the chance of getting moisture in the brake fluid. Use a large C-clamp and wood block with some cushioning (I used some shop towels) to compress the piston. Go slow and make sure you do not damage the caliper piston.
7. Remove the two 21mm caliper adapter bolts and remove the caliper adapter. (The 1st time the rotor is taken off requires the factory clips to be removed from the studs.)
8. Remove the rotor by loosening it with some hits from a dead blow mallet and then wiggling it the rest of the way off. If you are NOT replacing the rotors, be careful not to damage it. But if you are NOT replacing it… Why are you removing it?
9. If you are planning to paint your calipers... Now is the time while the calipers and caliper adapters are off giving you better access. I used Dupli-Color Caliper Paint kit. I include a spray cleaner for the calipers and caliper brackets, paint, and a brush.
 

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Discussion Starter · #2 ·
Part II - Install

This is the second part of the prvious thread. This part covers the installation of new rotors and pads.

ROTOR INSTALL
1. Install the rotor on the hub (front) or the axle shaft (rear)
2. Install the caliper adapter and the two 21mm bolts and tighten to 100 ft. lbs.
3. Install the disc brake pads into the caliper adapter
4. Install the disc brake caliper and the two bolts (13mm – Front 10mm – Rear) that secure the caliper.
5. Install the tire and wheel assembly
7. Lower the vehicle.
8. Apply the brakes several times to seat brake pads.
9. Burnish the pads. To do this drive the truck up to about 30 mph and apply medium pressure to the brakes so that you slow to about 5 mph. Make sure that you do NOT come to complete stop. Repeat this about six more times. Then take the truck up to about 45 mph and apply firm pressure to the brakes and slow to 5 mph. Repeat this process two to three more times, making sure that you do NOT stop. Next, drive the vehicle for about 15 minutes without applying the brakes to allow the rotors to cool.
 

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